Just found there is a known issue to be resolved in future kafka version:  
https://issues.apache.org/jira/browse/KAFKA-1554

The workaround mentioned here helped.

> The workaround is to delete all index files of size 10MB (the size of the 
> pre-allocated files), and restart. Index files will be re-created.

> find $your_data_directory -size 10485760c -name *.index #-delete


Thanks
Zakee



> On Mar 13, 2015, at 3:38 PM, Zakee <kzak...@netzero.net> wrote:
> 
> I did a shutdown of the cluster and then try to restart and see the below 
> error on one of the 5 brokers, I can’t restart this instance and not sure how 
> to fix this.
> 
> [2015-03-13 15:27:31,793] ERROR There was an error in one of the threads 
> during logs loading: java.lang.IllegalArgumentException: requirement failed: 
> Corrupt index found, index file 
> (/data/vol6/kafka/kafka82/Topic22-6/00000000000006256447.index) has non-zero 
> size but the last offset is 6256447 and the base offset is 6256447 
> (kafka.log.LogManager)
> [2015-03-13 15:27:31,795] FATAL [Kafka Server 5], Fatal error during 
> KafkaServer startup. Prepare to shutdown (kafka.server.KafkaServer)
> java.lang.IllegalArgumentException: requirement failed: Corrupt index found, 
> index file (/data/vol6/kafka/kafka82/Topic22-6/00000000000006256447.index) 
> has non-zero size but the last offset is 6256447 and the base offset is 
> 6256447
>        at scala.Predef$.require(Predef.scala:233)
>        at kafka.log.OffsetIndex.sanityCheck(OffsetIndex.scala:352)
>        at kafka.log.Log$$anonfun$loadSegments$5.apply(Log.scala:184)
>        at kafka.log.Log$$anonfun$loadSegments$5.apply(Log.scala:183)
>        at scala.collection.Iterator$class.foreach(Iterator.scala:727)
>        at scala.collection.AbstractIterator.foreach(Iterator.scala:1157)
>        at scala.collection.IterableLike$class.foreach(IterableLike.scala:72)
>        at scala.collection.AbstractIterable.foreach(Iterable.scala:54)
>        at kafka.log.Log.loadSegments(Log.scala:183)
>        at kafka.log.Log.<init>(Log.scala:67)
>        at 
> kafka.log.LogManager$$anonfun$loadLogs$2$$anonfun$3$$anonfun$apply$7$$anonfun$apply$1.apply$mcV$sp(LogManager.scala:142)
>        at kafka.utils.Utils$$anon$1.run(Utils.scala:54)
>        at 
> java.util.concurrent.Executors$RunnableAdapter.call(Executors.java:441)
>        at java.util.concurrent.FutureTask$Sync.innerRun(FutureTask.java:303)
>        at java.util.concurrent.FutureTask.run(FutureTask.java:138)
>        at 
> java.util.concurrent.ThreadPoolExecutor$Worker.runTask(ThreadPoolExecutor.java:886)
>        at 
> java.util.concurrent.ThreadPoolExecutor$Worker.run(ThreadPoolExecutor.java:908)
>        at java.lang.Thread.run(Thread.java:662)
> [2015-03-13 15:27:31,831] INFO [Kafka Server 5], shutting down 
> (kafka.server.KafkaServer)
> 
> 
> Thanks
> Zakee
> 
> 
> 

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